Architectural hierarchy of control for a fuel processor

ABSTRACT

A control technique for use in a fuel processor is disclosed. In one aspect, a control system includes a subsystem manager controller the operation of a respective physical subsystem for each of a plurality of physical subsystems in the fuel processor. The subsystem managers take their direction from a master control manager. In a second aspect, the subsystem managers collectively form a layer operating in conjunction with a second layer capable of interfacing the subsystem managers to their respective physical subsystems, a third layer capable of interfacing the subsystem managers with the second layer. In a third aspect, master control manager manages the operation of each physical subsystem through a respective subsystem manager, directs state transitions of the subsystem managers, and routs interaction between the subsystem managers from the master control manager.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to a fuel processor, and, moreparticularly, to a control system for a fuel processor.

2. Description of the Related Art

Fuel cell technology is an alternative energy source for moreconventional energy sources employing the combustion of fossil fuels. Afuel cell typically produces electricity, water, and heat from a fueland oxygen. More particularly, fuel cells provide electricity fromchemical oxidation-reduction reactions and possess significantadvantages over other forms of power generation in terms of cleanlinessand efficiency. Typically, fuel cells employ hydrogen as the fuel andoxygen as the oxidizing agent. The power generation is proportional tothe consumption rate of the reactants.

A significant disadvantage which inhibits the wider use of fuel cells isthe lack of a widespread hydrogen infrastructure. Hydrogen has arelatively low volumetric energy density and is more difficult to storeand transport than the hydrocarbon fuels currently used in most powergeneration systems. One way to overcome this difficulty is the use of“fuel processors” or “reformers” to convert the hydrocarbons to ahydrogen rich gas stream which can be used as a feed for fuel cells.Hydrocarbon-based fuels, such as natural gas, LPG, gasoline, and diesel,require conversion for use as fuel for most fuel cells. Current art usesmulti-step processes combining an initial conversion process withseveral clean-up processes. The initial process is most often steamreforming (“SR”), autothermal reforming (“ATR”), catalytic partialoxidation (“CPOX”), or non-catalytic partial oxidation (“POX”). Theclean-up processes are usually comprised of a combination ofdesulfurization, high temperature water-gas shift, low temperaturewater-gas shift, selective CO oxidation, or selective CO methanation.Alternative processes include hydrogen selective membrane reactors andfilters.

Thus, many types of fuels can be used, some of them hybrids with fossilfuels, but the ideal fuel is hydrogen. If the fuel is, for instance,hydrogen, then the combustion is very clean and, as a practical matter,only the water is left after the dissipation and/or consumption of theheat and the consumption of the electricity. Most readily availablefuels (e.g., natural gas, propane and gasoline) and even the less commonones (e.g., methanol and ethanol) include hydrogen in their molecularstructure. Some fuel cell implementations therefore employ a “fuelprocessor” that processes a particular fuel to produce a relatively purehydrogen stream used to fuel the fuel cell.

Although fuel cells have been around for over a hundred years, thetechnology is still considered immature. The reasons for this state aremany and difficult. Recent political, commercial, and environmentalconditions have, however, spurred an increased interest in fuel celltechnology. The increased interest has, in turn, generated a heightenedpace of technological development.

However welcome the heightened pace of development may be, it presentsproblems of its own. Fuel cell designs, particularly those with fuelprocessors, are typically complex. Consider the fuel processor designillustrated in U.S. patent application Ser. No. 10/006,963, entitled“Compact Fuel Processor for Producing a Hydrogen Rich Gas,” filed Dec.5, 2001, in the name of the inventors Curtis L. Krause, et al., andpublished Jul. 18, 2002, (Publication No. US2002/0094310 A1). The anodetailgas oxidizer temperature in this design is a function of catalystloading, air flow and its space velocity and oxygen to carbon ratio atgiven space velocities. The sheer number of factors, in itself, makescontrol of this temperature a difficult task. Furthermore, a change infuel type—for example, from natural gas to hydrogen—dramatically affectsall these variables. Thus, the difficult control problem is exacerbatedas the fuel processor design changes.

The present invention is directed to resolving, or at least reducing,one or all of the problems mentioned above.

SUMMARY OF THE INVENTION

A control technique for use in a fuel processor is disclosed. In oneaspect, a control system includes a subsystem manager controller theoperation of a respective physical subsystem for each of a plurality ofphysical subsystems in the fuel processor. The subsystem managers taketheir direction from a master control manager. In a second aspect, thesubsystem managers collectively form a layer operating in conjunctionwith a second layer capable of interfacing the subsystem managers totheir respective physical subsystems, a third layer capable ofinterfacing the subsystem managers with the second layer. In a thirdaspect, master control manager manages the operation of each physicalsubsystem through a respective subsystem manager, directs statetransitions of the subsystem managers, and routs interaction between thesubsystem managers from the master control manager.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be understood by reference to the followingdescription taken in conjunction with the accompanying drawings, inwhich like reference numerals identify like elements, and in which:

FIG. 1 illustrates one particular embodiment of a control systemimplemented in accordance with the present invention;

FIG. 2A and FIG. 2B conceptually illustrate a computing apparatus as maybe used in the implementation of the embodiment of FIG. 1;

FIG. 3 illustrates one particular embodiment of a fuel processorcontrolled in accordance with the present invention;

FIG. 4A-FIG. 4F detail the physical subsystems of the fuel processor inFIG. 3;

FIG. 5 depicts one particular embodiment of the control system of FIG. 1for use in controlling the fuel processor first shown in FIG. 3;

FIG. 6 illustrates an architectural hierarchy of a subsystem manager forthe control system first shown in FIG. 5 in accordance with the presentinvention;

FIG. 7 is a state machine for the physical subsystems of one particularembodiment of the present invention; and

FIG. 8 graphically illustrates the reforming process of the autothermalreformer of the fuel processor first shown in FIG. 3.

While the invention is susceptible to various modifications andalternative forms, the drawings illustrate specific embodiments hereindescribed in detail by way of example. It should be understood, however,that the description herein of specific embodiments is not intended tolimit the invention to the particular forms disclosed, but on thecontrary, the intention is to cover all modifications, equivalents, andalternatives falling within the spirit and scope of the invention asdefined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

Illustrative embodiments of the invention are described below. In theinterest of clarity, not all features of an actual implementation aredescribed in this specification. It will of course be appreciated thatin the development of any such actual embodiment, numerousimplementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which will vary from one implementation toanother. Moreover, it will be appreciated that such a developmenteffort, even if complex and time-consuming, would be a routineundertaking for those of ordinary skill in the art having the benefit ofthis disclosure.

The present invention is generally directed to method and apparatus forcontrolling a “fuel processor,” or “reformer,” i.e., an apparatus forconverting hydrocarbon fuel into a hydrogen rich gas. The term “fuelprocessor” shall be used herein. In the embodiment illustrated herein,the method and apparatus control a compact processor for producing ahydrogen rich gas stream from a hydrocarbon fuel for use in fuel cells.However, other fuel processors may be used in alternative embodiments.Furthermore, other possible uses are contemplated for the apparatus andmethod described herein, including any use wherein a hydrogen richstream is desired. The method and apparatus may also be used inembodiments not applicable to the production of gas streams.Accordingly, while the invention is described herein as being used inconjunction with a fuel cell, the scope of the invention is not limitedto such use.

FIG. 1 illustrates one particular embodiment of a control system 100designed, built, and operated in accordance with the present invention.The control system 100 comprises a master control manager 102, and aplurality of physical subsystem managers 104. The number of subsystemmanagers 104 is not material to the invention. Accordingly, FIG. 1illustrates N subsystem managers 104, designated SUBSYSTEMMANAGER₀-SUBSYSTEM MANAGER_(N). In theory, the number N may be anynumber, although those skilled in the art having the benefit of thisdisclosure will appreciate that certain practical limitations will arisefrom implementation specific details. Nevertheless, the number N ofsubsystem managers 104 is not material to the practice of the invention.

The control system 100 is largely software implemented on a computingapparatus, such as the rack-mounted computing apparatus 200 isillustrated in FIG. 2A and FIG. 2B. Note that the computing apparatus200 need not be rack-mounted in all embodiments. Indeed, this aspect ofany given implementation is not material to the practice of theinvention. The computing apparatus 200 may be implemented as a desktoppersonal computer, a workstation, a notebook or laptop computer, or evenan embedded processor.

The computing apparatus 200 illustrated in FIG. 2A and FIG. 2B includesa processor 205 communicating with storage 210 over a bus system 215.The storage 210 may include a hard disk and/or random access memory(“RAM”) and/or removable storage such as a floppy magnetic disk 217 andan optical disk 220. The storage 210 is encoded with a data structure225 storing the data set acquired as discussed above, an operatingsystem 230, user interface software 235, and an application 265. Theuser interface software 235, in conjunction with a display 240,implements a user interface 245. The user interface 245 may includeperipheral I/O devices such as a key pad or keyboard 250, a mouse 255,or a joystick 260. The processor 205 runs under the control of theoperating system 230, which may be practically any operating systemknown to the art. The application 265 is invoked by the operating system230 upon power up, reset, or both, depending on the implementation ofthe operating system 230. In the illustrated embodiment, the application265 includes the control system 100 illustrated in FIG. 1.

Thus, at least some aspects of the present invention will typically beimplemented as software on an appropriately programmed computing device,e.g., the computing apparatus 200 in FIG. 2A and FIG. 2B. Theinstructions may be encoded on, for example, the storage 210, the floppydisk 217, and/or the optical disk 220. The present invention thereforeincludes, in one aspect, a computing apparatus programmed to perform themethod of the invention. In another aspect, the invention includes aprogram storage device encoded with instructions that, when executed bya computing apparatus, perform the method of the invention.

Some portions of the detailed descriptions herein are consequentlypresented in terms of a software implemented process involving symbolicrepresentations of operations on data bits within a memory in acomputing system or a computing device. These descriptions andrepresentations are the means used by those in the art to mosteffectively convey the substance of their work to others skilled in theart. The process and operation require physical manipulations ofphysical quantities. Usually, though not necessarily, these quantitiestake the form of electrical, magnetic, or optical signals capable ofbeing stored, transferred, combined, compared, and otherwisemanipulated. It has proven convenient at times, principally for reasonsof common usage, to refer to these signals as bits, values, elements,symbols, characters, terms, numbers, or the like.

It should be borne in mind, however, that all of these and similar termsare to be associated with the appropriate physical quantities and aremerely convenient labels applied to these quantifies. Unlessspecifically stated or otherwise as may be apparent, throughout thepresent disclosure, these descriptions refer to the action and processesof an electronic device, that manipulates and transforms datarepresented as physical (electronic, magnetic, or optical) quantitieswithin some electronic device's storage into other data similarlyrepresented as physical quantities within the storage, or intransmission or display devices. Exemplary of the terms denoting such adescription are, without limitation, the terms “processing,”“computing,” “calculating,” “determining,” “displaying,” and the like.

The control system 100 controls, in the illustrated embodiment, a fuelprocessor, i.e., the fuel processor 300 in FIG. 3. The fuel processor300 comprises several modular physical subsystems, namely:

-   -   an autothermal reformer (“ATR”) 302 that performs the        oxidation-reduction reaction that reforms the fuel input to the        fuel processor 300 into a reformate for a fuel cell 303;    -   an oxidizer (“ox”) 304, which is an anode tailgas oxidizer        (“ATO”) in the illustrated embodiment, that mixes steam, fuel,        and air to create a fuel mixture delivered as a process feed        stream to the ATR 302;    -   a fuel subsystem 306, that delivers an input fuel (natural gas,        in the illustrated embodiment) to the oxidizer 304 for mixing        into the process feed stream delivered to the ATR 302;    -   a water subsystem 308, that delivers water to the oxidizer 304        for mixing into the process feed stream delivered to the ATR        302;    -   an air subsystem 310, that delivers air to the oxidizer 304 for        mixing into the process feed stream delivered to the ATR 302;        and    -   a thermal subsystem 312, that controls temperatures in the        operation of the ATR 302 by circulating a coolant (e.g., water)        therethrough.        Particular implementations of the ATR 302, oxidizer 304, fuel        subsystem 306, water subsystem 308, air subsystem 310, and        thermal subsystem 312 are illustrated in FIG. 4A-FIG. 4F.

FIG. 4A depicts one particular implementation of the fuel subsystem 306.The fuel subsystem 306 includes a fuel supply 402 and provides feedsATO1, ATO2 to two different parts of the oxidizer 304. As previouslymentioned, the fuel in the illustrated embodiment is natural gas, butmay be some other type of hydrocarbon. The hydrocarbon fuel may beliquid or gas at ambient conditions as long as it can be vaporized. Asused herein the term “hydrocarbon” includes organic compounds having C—Hbonds which are capable of producing hydrogen from a partial oxidationor steam reforming reaction. The presence of atoms other than carbon andhydrogen in the molecular structure of the compound is not excluded.Thus, suitable fuels for use in the method and apparatus disclosedherein include, but are not limited to hydrocarbon fuels such as naturalgas, methane, ethane, propane, butane, naphtha, gasoline, and dieselfuel, and alcohols such as methanol, ethanol, propanol, and the like. ASulphur trap 408 receives the fuel from the fuel supply 402 though acheck valve 404 and a solenoid valve 406. The de-sulphured fuel is thenfiltered by the filter 410 and fed through two lines 411, 413 eachincluding a control valve 412 and a flow meter 414, to the oxidizer 304.

FIG. 4B depicts one particular implementation of the water subsystem308. A tank 416 receives water from a water supply 418 through a checkvalve 404 and a solenoid valve 406. In the illustrated embodiment, thetank 416 also receives water through a return 420 from the cathode (notshown) of the fuel cell 303. Pressure and volume in the tank 416 arealso controlled through a pressure relief, check valve 426 and a drain417 through a solenoid valve 406 to a drain pan 419. Water 424 in thetank 416 is pumped by the pump 421 through the line 425, including thefilter 410 and the mass flow meter 427, to the oxidizer 304 under thedirection of the controller 428. A damper 430 damps oscillations orfluctuations in the pressure of the pumped water 424 on its way to theoxidizer 304. The air 423 is also fed to the oxidizer 304 via the line427.

FIG. 4C depicts one particular implementation of the air subsystem 310.A compressor 432, including a motor 434, receives filtered air from theambient atmosphere via an air intake 436, a filter 410, and a flow meter414 and compresses it into a tank 438. The air from the tank 438 is thendistributed through two feeds ATO6, ATO7 over the lines 440, 442,including the flow meters 414 and control valves 444, 446, to theoxidizer 304. The air from the tank 438 is also distributed through afeed ATR1 over the line 447 including a flow meter 414 and a controlvalve 446 to the ATR 302.

FIG. 4D depicts one particular implementation of the oxidizer 304. Theoxidizer 304 receives fuel, water, and air through the feeds ATO2, ATO3,ATO5, ATO7 via the lines 413, 440, 427, 429, described above, from thefuel subsystem 306, water subsystem 308, the air subsystem 310, and theATR 302 through a plurality of check valves 426. The feed ATO5 is from awater separation system (discussed below) associated with the ATR 302.Hot air 429 from the cathode (not show) of the fuel cell 303 is alsoreturned to the oxidizer 304. Exhaust 431 from the anode (not shown) ofthe fuel cell 303 is returned to a water separator 448, that separatesout the water that is drained via the solenoid valve 406 to the drainpan 419. The dehydrated anode return is then supplied to the oxidizer304 via a check valve 426 through the line 450. The fuel, air, anddehydrated anode return are then mixed in the mixer 452, beforeintroduction to the tank 454 of the oxidizer 304. The resultant mixtureis then heated by the electric heater 456.

Still referring to FIG. 4D, the oxidizer 304 also receives fuel, air,and water from the fuel subsystem 306, the water subsystem 308, and theair subsystem 310 through the feeds ATO1, ATO6, ATO3 over the lines 411,442, and 425, respectively, described above. The lines 411 and 442 areprotected by check valves 426. Air and fuel received over the lines 411,and 442 enter the enclosed coil 458. Water received over the line 425enters the enclosed coil 460. The heated air, water, and fuel mixture inthe tank 454 heats the contents of the enclosed coils 458, 460, whichare then mixed in the mixer 462 and provided to the ATR 302 through thefeed ATR2 over the line 464. The oxidizer 304 is rented to an exhaust463 through a line 465.

FIG. 4E depicts one particular implementation of the thermal subsystem312. Water 466 is drawn from a water supply 468 into a tank 416. Notethat the water supply 468 differs from the water supply 418 of the watersubsystem 308, shown in FIG. 4B. The water 424 drawn from the watersupply 418 is, in the illustrated embodiment, de-ionized, whereas thewater 466 is not. The water 466 is circulated to various parts of theATR 302 and subsystems associated with it through the feeds ATR3, PROX1,L1, L2 over the lines 471-475. Water 466 previously circulated to theATR 302 is returned to the thermal subsystem 312 through the feed TS1over the line 476. Heat introduced to the water 466 by the ATR 302components is dumped to the environment through the heat exchangers 478.The illustrated embodiment also employs fans 480 to facilitate this heatexchange.

FIG. 4F depicts one particular implementation of the ATR 302. The ATR302 comprises several stages 482 a-482 e, including numerous heatexchangers 478 and electric heaters 456. Each of the heat exchangers 478receives temperature controlled water 466 from the thermal subsystem 312(shown best in FIG. 4E) over the lines 470-472 and returns it over thelines 476. The exceptions are the heat exchangers 478 in thepreferential oxidizing (“prox”) stage 482, which receives the water 466from the thermal subsystem 312 over the line 473 and returns it to awater tank 416 via line 476 and the feed TS1. The reformate gas exitingthe ATR 302 passes through a preferential oxidizer 486, is heated by theheat exchanger 478, dehydrated by the water separator 448, filtered, andsupplied to the anode (not shown) of the fuel cell 303 (shown in FIG.3). The illustrated embodiment also includes a burst disk 484 that, whenthe ATR 302 overpressures, bursts so that the content of the ATR 302 isdumped to the oxidizer 304 via the line 440 and the feed ATO7.

Returning now to FIG. 3, each of the ATR 302, oxidizer 304, fuelsubsystem 306, water subsystem 308, air subsystem 310, and thermalsubsystem 312 constitutes a physical subsystem controlled by one of thesubsystem managers 104. Thus, one particular implementation of thecontrol system 100 for use with the particular fuel processor 300 inFIG. 3 is shown in FIG. 5 comprises:

-   -   a master control manager 502 that manages the control of the        fuel processor 300 through the subsystem managers:    -   a fuel subsystem manager 504 that controls the delivery of fuel        to the ATO 306 for mixing into the process feed stream delivered        to the ATR 302;    -   a water subsystem manager 506 that controls delivery of water to        the ATO 306 for mixing into the process feed stream delivered to        the ATR 302;    -   an air subsystem manager 508 that controls delivery of air to        the ATO 306 for mixing into the process feed stream delivered to        the ATR 302;    -   an ATO subsystem manager 510 that controls the mixing of steam,        fuel, and air to create a fuel mixture delivered as a process        feed stream to the ATR 302;    -   an ATR subsystem manager 512 that controls the        oxidation-reduction reaction in the ATR 302 that reforms the        fuel input to the fuel processor 300 into a reformate for the        fuel cell 303; and    -   a thermal subsystem manager 514 controls temperatures in the        operation of the ATR 302 through the thermal subsystem 312.        Thus, each of the subsystem managers 504-514 controls the        operation of a respective physical subsystem 302, 304-312.

The control system 500 further includes additional layers thatcontribute to its is modularity in a hierarchical fashion. Moreparticularly, the control system 500 includes a hardware-dependent layer516 and a “compatibility” layer 518. Aspects of the controlfunctionality that are hardware-dependent are segregated into thehardware-dependent layer 516. For example, referring to FIG. 4A, toincrease the flow of fuel 402 to the oxidizer 304, one or both of thecontrol valves 414 is opened. A control signal (not shown) istransmitted from the control system 500 to the actuator (also not shown)of the control valve(s) 414, and the characteristics of this signal arehardware dependent. The functionality of actually generating andtransmitting this control signal is segregated into thehardware-dependent layer 516. Thus, if the hardware in, for example, thefuel subsystem 306 is changed out from one model to another, then onlythe hardware-dependent layer 516 needs to be amended. The compatibilitylayer 518 converts instructions issued by the subsystem managers 504-514so that they are compatible with the hardware of the fuel processor 300.For instance, one subsystem manager 504-514 may request an event using aparticular unit of measurement. The hardware needed to implement therequest may take instructions in a second unit of measurement. Thecompatibility layer 518 will translate the instruction issued by thesubsystem managers 504-514 in the first unit of measurement to thesecond unit of measurement employed by the hardware so it can beimplemented by the hardware-dependent layer 516.

The illustrated embodiment of the control system 500 furthermoreincludes a diagnostic layer 520 that also contributes to its modularityin a hierarchical fashion. Each of the subsystem managers 504-514monitors its respective physical subsystem 302, 304-312 for errorconditions. More particularly, the subsystem managers 504-514 monitorfor “shutdown” conditions, i.e., error conditions sufficiently importantthey warrant shutting down the fuel processor 300. The error conditionsdetected by the subsystem managers 504-514 are reported to the mastercontrol manager 502 through the diagnostic layer 520.

Each of the subsystem managers 504-514 also embodies a modular internalstructure 600 conceptually illustrated in FIG. 6. Each of the subsystemmanagers 504-514 employs this modular internal structure 600 to conductits business in the management of the respective physical subsystem 302,304-312. Each of the subsystem managers 504-514 includes:

-   -   an information exchange module 605 through which the particular        subsystem manager 504-514 determines the feasibility of        implementing events requested by other subsystem managers        504-514 through the master control manager 502 and identifies        the actions for implementing requested events;    -   a diagnostic module 610 that communicates with the diagnostic        layer 520 through the information exchange module 605 to report        error conditions;    -   a physical module 615 with which the information exchange module        605 consults to identify the actions for implementing requested        events and with which the diagnostic module communicates to        obtain information regarding error conditions; and    -   a control module 620 with which the physical module 615 consults        to determine which actions are to be taken to implement a        requested event and through which communicates with the        hardware-dependent layer 516 through the compatibility layer 518        to obtain the information for such determination.        In alternative embodiments of the control system 500 omitting        the diagnostic layer 520, the diagnostic module 610 may be        omitted from the subsystem managers 504-514.

Returning to FIG. 5, in the illustrated embodiment, the subsystemmanagers 504-514 cooperate with each other by communicating requestsfrom their information exchange modules 605 through the master controlmanager 502. For instance, consider a situation in which the oxidizer304, first shown in FIG. 3, senses a drop in pressure in the feed fromthe fuel subsystem 306, also first shown in FIG. 3. The ATO subsystemmanager 510 may request that the supply of fuel increase. In theparlance of the illustrated embodiment, a fuel increase would be an“event.” The ATO subsystem manager 510 issues the request through itsinformation exchange module 605, shown in FIG. 6, which communicates therequest to the master control manager 502. The master control manager502 forwards the request to the appropriate physical subsystemmanager—the fuel subsystem manager 504, in this case.

The fuel subsystem manager 504 receives the request via its owninformation exchange module 605, which checks to see if it is in theproper operational state (discussed further below) to implement therequest. The fuel subsystem manager 504 then implements the requestedevent if it is permissible and feasible. The information exchange module605 instructs the physical module 615 to implement the requested event.The information exchange module 605 queries the controller module 620about which actions need to be taken. The information exchange module605 then informs the physical module 615 of those actions that need tobe taken. The physical module 615 then issues such an instruction to thehardware actuator (not shown) through the hardware dependent layer 516via the compatibility layer 518.

The master control manager 502 also controls the operational state ofthe overall system 300 through the subsystem managers 504-514. Consider,for instance, the state diagram 700 in FIG. 7, which represents theoperational states and the transition among them of the subsystemmanagers 504-514. Each of the subsystem managers 504-514 transitionsthrough eight different states, although not all eight in everyoperational cycle:

-   -   an “off” state 702;    -   a “manager check” state 704, in which the subsystem managers        504-514 check the operational readiness of their respective        physical subsystem 302-312;    -   a “manual” state 706, in which an operator can direct operation        of the overall system;

a “preheat” state 708, in which the heating elements and fluids of theoverall system 300 are preheated, or pre-cooled, to their designatedlevels for normal operation;

-   -   a “startup” state 710, in which the overall system 300 begins        operation under start-up conditions;    -   a “run” state 712, in which the overall system 300 operates        under steady-state conditions;    -   a “shutdown” state 714, in which the physical subsystems of the        overall system shutdown their operation to a planned end of an        operational cycle; and    -   an “emergency shutdown” state 716, in which the physical        subsystems are shut down in response to the occurrence and        detection of an emergency condition in one or more of the        physical subsystems.        Although each of the subsystem managers 504-514 transitions        through the same eight states, the tasks assigned to each of the        subsystem managers 504-514 will be unique in light of the        requirements of their respective physical subsystem 302-312. For        example, the tasks performed by the fuel subsystem manager 504        in the run state 712 will differ from the tasks of the ATR        subsystem manager 512 in the run state, given the differences in        the operation and function of the fuel subsystem 306 and the ATR        302, both shown in FIG. 3.

Returning to FIG. 7, coming out of the off state 702, the subsystemmanagers 504-514 may transition into either the manager check state 704or the manual state 706. From the manual state 706, the subsystemmanagers 504-514 transition only to either the shutdown state 714 or theemergency shutdown state 716. From the manager check state 704, thesystem managers 504-514 may transition through the preheat state 708,startup state 710, and run state 712 in that order. The subsystemmanagers 504-514 can transition into either of the shutdown state 714and the emergency shutdown state 716 from any of the other states.

Referring now to FIG. 5 and FIG. 7, an operator chooses whether to enterthe manual state 706 on powering up or initializing the system, i.e.,exiting the off state 702. If the operator does not choose the manualstate 706, the master control manager 502 assumes control. In the manualstate 706, the operator can choose a percentage of operational capacityand the system ramps up to the setpoints of the specified level, butstill applies control logic. That is, the subsystem managers 504-514still cooperate with one another through the master control manager 500as described above.

Assuming now that the operator does not assume manual control, themaster control manager 502 sends a signal to each of the subsystemmanagers 504-514 to transition to the manager check state 704. Each ofthe subsystem managers 504-514 transitions to the manager check state704. Each of the subsystem managers 504-514 then performs its tasksassociated with the manager check state 704. When the individualsubsystem managers 504-514 have completed their tasks associated withthe manager check state 704, they signal that fact to the master controlmanager 502. The master control manager 502 waits until all thesubsystem managers 504-514 have signaled they are through, and thesignals the subsystem managers 504-514 to transition to the preheatstate 708.

This procedure is repeated as the subsystem managers 504-514 transitionthrough the remaining states. Note that the subsystem managers 504-514transition to the next state only when signaled to do so by the mastercontrol manager 502. Note also that the master control manager 502 onlysignals the subsystem managers 504-514 to transition when all of thesubsystem managers 504-514 are ready to do so. Thus, the subsystemmanagers 504-514 transition through their states in a synchronizedfashion under the direction of the master control manager 502.

Returning to FIG. 5, the master control manager 502 therefore controlsthe overall operation of the fuel processor 300 in two ways. First,communications between various subsystem managers are routed through themaster control manager 502. Second, the master control manager 502controls the operational states of the subsystem managers 504-514.

Referring now to FIG. 3 and FIG. 5, the operation of the fuel processor300 under the control of the control system 500 will now be described.On power up or reset, the fuel processor 300 and the control system 500transition from the off state 702, shown in FIG. 7, to either themanager check state 704 or the manual state 706, depending on operatorinput. Again assuming the operator does not assume manual control, themaster control manager 502 signals the subsystem managers 504-514 totransition to the manager check state 704, in which the subsystemmanagers 504-514 check the operational readiness of their respectivephysical subsystem. Once each of the subsystem managers 504-514 signalsthe master control manager 502 that their respective physical subsystemhas passed the manager check, the master controller 502 signals thesubsystem managers 504-514 to transition to the preheat state 708, inwhich the heating elements and fluids of the respective physicalsubsystems are preheated, or pre-cooled, to their designated levels fornormal operation.

Once all the subsystem managers 504-514 signal that their respectivephysical subsystem has completed it's preheat tasks, the master controlmanager 502 signals them to transition to the startup state 710, inwhich the overall system 300 begins operation under start-up conditions.As will be appreciated by those skilled in the art having the benefit ofthis disclosure, the fuel processor 300 cannot simply step intoproduction. For instance, the oxidizer 304 cannot begin to mix processfeed stream until it has fuel, water, and air to mix. Similarly, the ATR302 cannot begin to reform the fuel until it has received sufficientprocess feed stream from the oxidizer 304. Thus, in the startup state710, out-of-range pressures, volumes, etc. that do not trigger, shutdownerror conditions are tolerated until the fuel processor 300 reachessteady state operations.

Once all the subsystem managers 504-514 signal that their respectivephysical subsystems have reached steady-state operational conditions,the master control manager 502 signals them to transition to the runstate 712. In the run state 712, the overall system 300 operates understeady-state conditions. The overall function of the fuel processor 300is to reform the fuel 402, shown in FIG. 4A, for use by the fuel cell303. Thus, the operation of the fuel processor 300 centers around theoperation of the ATR 302 and the delivery of fuel (shown in FIG. 4A),air (shown in FIG. 4C), and water (shown in FIG. 4B) to the ATR 302 fromthe fuel subsystem 306, water subsystem 308, and air subsystem 310.

FIG. 8 depicts a general process flow diagram illustrating the processsteps included in the illustrative embodiments of the present invention.The following description associated with FIG. 8 is adapted from U.S.patent application Ser. No. 10/006,963, entitled “Compact Fuel Processorfor Producing a Hydrogen Rich Gas,” filed Dec. 5, 2001, in the name ofthe inventors Curtis L. Krause, et al., and published Jul. 18, 2002,(Publication No. US2002/0094310 A1). One of skill in the art shouldappreciate that a certain amount of progressive order is needed in theflow of the reactants trough the reactors disclosed herein. The fuelprocessor 300 feeds include a hydrocarbon fuel, oxygen, and water. Theoxygen can be in the form of air, enriched air, or substantially pureoxygen. The water can be introduced as a liquid or vapor. Thecomposition percentages of the feed components are determined by thedesired operating conditions, as discussed below. The fuel processoreffluent stream from of the present invention includes hydrogen andcarbon dioxide and can also include some water, unconvertedhydrocarbons, carbon monoxide, impurities (e.g., hydrogen sulfide andammonia) and inert components (e.g., nitrogen and argon, especially ifair was a component of the feed stream).

Process step A is an autothermal reforming process in which tworeactions, a partial oxidation (formula I, below) and an optional steamreforming (formula II, below), performed in the modular 482 a and 482 bin FIG. 4F are combined to convert the feed stream F into a synthesisgas containing hydrogen and carbon monoxide. Formulas I and II areexemplary reaction formulas wherein methane is considered as thehydrocarbon:CH₄+½O₂→2H₂+CO  (I)CH₄+H₂O→3H₂+CO  (II)The fuel stream F is received by the ATR 302 from the oxidizer 304 overthe line 434, as shown in FIG. 4D and FIG. 4F. A higher concentration ofoxygen in the feed stream favors partial oxidation whereas a higherconcentration of water vapor favors steam reforming. The ratios ofoxygen to hydrocarbon and water to hydrocarbon are thereforecharacterizing parameters that affect the operating temperature andhydrogen yield.

The operating temperature of the autothermal reforming step A can rangefrom about 550° C. to about 900° C., depending on the feed conditionsand the catalyst. The ratios, temperatures, and feed conditions are allexamples of parameters controlled by the control system of the presentinvention. The illustrated embodiment uses a catalyst bed of a partialoxidation catalyst in module 482 a with or without a steam reformingcatalyst.

Returning to FIG. 8, process step B is a cooling step performed in themodule 482 c of FIG. 4F for cooling the synthesis gas stream fromprocess step A to a temperature of from about 200° C. to about 600° C.,preferably from about 375° C. to about 425° C., to optimize thetemperature of the synthesis gas effluent for the next step. Thiscooling may be achieved with heat sinks, heat pipes or heat exchangersdepending upon the design specifications and the need to recover/recyclethe heat content of the gas stream using any suitable type of coolant.The illustrated embodiment uses water 466 received from the water 466over the line 470 as shown in FIG. 4E and FIG. 4F.

Returning again to FIG. 8, process step C is a purifying step, performedin the module 482 c, and employs zinc oxide as a hydrogen sulfideabsorbent. One of the main impurities of the hydrocarbon stream issulfur, which is converted by the autothermal reforming step A tohydrogen sulfide. The processing core used in process step C preferablyincludes zinc oxide and/or other material capable of absorbing andconverting hydrogen sulfide, and may include a support (e.g., monolith,extrudate, pellet, etc.). Desulfurization is accomplished by convertingthe hydrogen sulfide to water in accordance with the following reactionformula III:H₂S+ZnO→H₂O+ZnS  (III)The reaction is preferably carried out at a temperature of from about300° C. to about 500° C., and more preferably from about 375° C. toabout 425° C. This temperature is also controlled by the control systemof the present invention.

Referring once more to FIG. 8, the effluent stream may then be sent to amixing step D performed in module 482 d, in which water received fromthe water subsystem 308 is optionally added to the gas stream. Theaddition of water lowers the temperature of the reactant stream as itvaporizes and supplies more water for the water gas shift reaction ofprocess step E (discussed below). The water vapor and other effluentstream components are mixed by being passed through a processing core ofinert materials such as ceramic beads or other similar materials thateffectively mix and/or assist in the vaporization of the water.Alternatively, any additional water can be introduced with feed, and themixing step can be repositioned to provide better mixing of the oxidantgas in the CO oxidation step G (discussed below). This temperature isalso controlled by the control system of the present invention.

Returning to FIG. 8, process step E, performed in Module 482 e is awater gas shift reaction that converts carbon monoxide to carbon dioxidein accordance with formula IV:H₂O+CO→H₂+CO₂  (IV)The concentration of carbon monoxide should preferably be lowered to alevel that can be tolerated by fuel cells, typically below 50 ppm.Generally, the water gas shift reaction can take place at temperaturesof from 150° C. to 600° C. depending on the catalyst used. Under suchconditions, most of the carbon monoxide in the gas stream is convertedin this step. This temperature and concentration are more parameterscontrolled by the control system of the present invention.

Returning again to FIG. 8, process step F, performed in Module 482 e, isa cooling step performed in the illustrated embodiment by a heatexchanger 478. The heat exchanger 478 reduces the temperature of the gasstream to produce an effluent having a temperature preferably in therange of from about 90° C. to about 150° C. Oxygen from the airsubsystem 310 is also added to the process in step F over the line 498,as shown in FIG. 4C and FIG. 4F. The oxygen is consumed by the reactionsof process step G described below.

Process step G, performed in module 482 g, is an oxidation step whereinalmost all of the remaining carbon monoxide in the effluent stream isconverted to carbon dioxide. The processing is carried out in thepresence of a catalyst for the oxidation of carbon monoxide. Tworeactions occur in process step G: the desired oxidation of carbonmonoxide (formula V) and the undesired oxidation of hydrogen (formulaVI) as follows:CO+½O₂→CO₂  (V)H₂+½O₂→H₂O  (VI)

The preferential oxidation of carbon monoxide is favored by lowtemperatures. Since both reactions produce heat it may be advantageousto optionally include a cooling element such as a cooling coil disposedwithin the process. The operating temperature of process is preferablykept in the range of from about 90° C. to about 150° C. Process step Greduces the carbon monoxide level to preferably less than 50 ppm, whichis a suitable level for use in fuel cells.

The effluent exiting the fuel processor is a hydrogen rich gascontaining carbon dioxide and other constituents which may be presentsuch as water, inert components (e.g., nitrogen, argon), residualhydrocarbon, etc. Product gas may be used as the feed for a fuel cell orfor other applications where a hydrogen rich feed stream is desired.Optionally, product gas may be sent on to further processing, forexample, to remove the carbon dioxide, water or other components.

Eventually, the operational cycle ends. If the end is planned, then themaster control manager 502 signals the subsystem managers 504-514 totransition to the shutdown state 714 at an appropriate time. Asmentioned above, the subsystem managers 504-514 monitor, through theirdiagnostic module 610, shown in FIG. 6, their respective physicalsubsystems for the occurrence of error conditions. Some error conditionswarrant shutting down operation of the fuel processor 300. If such a“shutdown” error condition is detected, the subsystem manager 504-514detecting it reports it through the diagnostic module 610 and thediagnostic layer 520, shown in FIG. 5, to the master control manager502. The master control module 502 then signals the subsystem managers504-514 to transition to the emergency shutdown state 716.

The modular design resulting from the hierarchical nature of the presentinvention permits flexibility in expansion of the control system. Wholesubsystems can be removed, added, and/or replaced for testing,evaluating, and modifying subsystem designs without having to make majoradjustments to the control system. None of the control algorithms arehardware-dependent, except for the hardware dependent layer, whichcontains instrument calibration data. Thus, various types of instrumentscan be added, removed, or replaced without affecting the control systemas a whole, and without requiring a lot of reprogramming. The presentinvention therefore allows rapid and easy expansion of the processcontrol system and facilitates seamless plug-ins of new subsystems. Italso permits independent or different teams of developers to quicklycreate the control software for various physical subsystems from arelatively simple specification. This asset is particularly useful inrapidly evolving technologies, such as fuel processor/fuel cell design,with complex control systems.

This concludes the detailed description. The particular embodimentsdisclosed above are illustrative only, as the invention may be modifiedand practiced in different but equivalent manners apparent to thoseskilled in the art having the benefit of the teachings herein.Furthermore, no limitations are intended to the details of constructionor design herein shown, other than as described in the claims below. Itis therefore evident that the particular embodiments disclosed above maybe altered or modified and all such variations are considered within thescope and spirit of the invention. Accordingly, the protection soughtherein is as set forth in the claims below.

1. A method for controlling a fuel processor comprising a plurality ofphysical subsystems, the method comprising: managing the operation ofeach physical subsystem through a respective subsystem manager;directing state transitions of the subsystem managers from a mastercontrol manager; and routing interaction between the subsystem managersfrom the master control manager.
 2. The method of claim 1, whereinmanaging the operation of each physical subsystem includes invoking acontrol module, an information exchange module, and a control module. 3.The method of claim 2 wherein managing the operation further includesinvoking a diagnostics module.
 4. The method of claim 1, whereindirecting state transitions of the subsystem managers includes directingstate transitions: to an off state; to at least one operational statefrom the off state; and to at least one shutdown state from any of theoperational states.
 5. The method of claim 4, wherein the at least oneoperational state comprises at least one of: a manual state into whichthe subsystem may transition from the off state; a manager check stateinto which the subsystem may transition from the off state; a preheatstate into which the subsystem may transition from the manager checkstate; a startup state into which the subsystem may transition from thepreheat state; and a run state into which the subsystem may transitionfrom the startup state.
 6. The method of claim 4, wherein the at leastone shutdown state includes at least one of: a standard shutdown state;and an emergency shutdown state.
 7. An apparatus for controlling a fuelprocessor comprising a plurality of physical subsystems, the apparatuscomprising: means for managing the operation of each physical subsystemthrough a respective subsystem manager; means for directing statetransitions of the subsystem managers from a master control manager; andmeans for routing interaction between the subsystem managers from themaster control manager.
 8. The apparatus of claim 7, wherein the meansfor managing the operation of each physical subsystem includes means forinvoking a control module, an information exchange module, and a controlmodule.
 9. The apparatus of claim 8, wherein the means for managing theoperation further includes means for invoking a diagnostics module. 10.The apparatus of claim 7, wherein the means for directing statetransitions of the subsystem managers includes means for directing statetransitions: to an off state; to at least one operational state from theoff state; and to at least one shutdown state from any of theoperational states.
 11. The apparatus of claim 10, wherein the at leastone operational state comprises at least one of: a manual state intowhich the subsystem may transition from the off state; a manager checkstate into which the subsystem may transition from the off state; apreheat state into which the subsystem may transition from the managercheck state; a startup state into which the subsystem may transitionfrom the preheat state; and a run state into which the subsystem maytransition from the startup state.
 12. The apparatus of claim 10,wherein the at least one shutdown state includes at least one of: astandard shutdown state; and an emergency shutdown state.
 13. A programstorage medium encoded with instructions that, when executed by acomputer, performs a method for controlling a fuel processor comprisinga plurality of physical subsystems, the method comprising: managing theoperation of each physical subsystem through a respective subsystemmanager; directing state transitions of the subsystem managers from amaster control manager; and routing interaction between the subsystemmanagers from the master control manager.
 14. The program storage mediumof claim 13, wherein managing the operation of each physical subsystemin the encoded method includes invoking a control module, an informationexchange module, and a control module.
 15. The program storage medium ofclaim 13, wherein directing state transitions of the subsystem managersin the encoded method includes directing state transitions: to an offstats; to at least one operational state from the off state; and to atleast one shutdown state from any of the operational states.
 16. Acomputer programmed to perform a method for controlling a fuel processorcomprising a plurality of physical subsystems, the method comprising:managing the operation of each physical subsystem through a respectivesubsystem manager; directing state transitions of the subsystem managersfrom a master control manager; and routing interaction between thesubsystem managers from the master control manager.
 17. The programmedcomputer of claim 16, wherein managing the operation of each physicalsubsystem in the programmed method includes invoking a control module,an information exchange module, and a control module.
 18. The programmedcomputer of claim 16, wherein directing state transitions of thesubsystem managers in the programmed method includes directing statstransitions: to an off state; to at least one operational state from theoff state; and to at least one shutdown state from any of theoperational states.